FSE Installs New Chiller

November 2010

At FSE’s NIOSH Taft Laboratory project site in Cincinnati, one of the existing York 220-ton screw compressors had failed.

  • Bad News - It was going to cost $110,000 to replace the compressor on this 15-year-old machine.


  • Good News - A new Trane chiller with two (2) screw compressors and two (2) circuits could be purchased for $90,000. The increased part load control and redundancy of two (2) self-contained refrigerant circuits made this an easy decision. Purchase a new chiller with two (2) compressors for $90,000 instead of installing one (1) new compressor in a 15-year-old machine.


  • More Good News - The rigging was accomplished by Fenton Rigging at no cost to the NIOSH client. In return for the privilege of keeping the old chiller and separating the metals for sale as scrap, Fenton
    • Received the new chiller in their yard;
    • Transported it to the NIOSH Taft Laboratory site and set the new chiller in place;
    • Removed the old chiller from the site;
    • And completed this all in one day.

  • Still More Good News - Because FSE’s onsite workforce is skilled in self-performing cutting, fabricating and welding, the six-inch condenser water and chiller water piping:
    • self-performing the required six (6) cable 500 MCM wire electrical connection, including 4-inch conduit;

    • self-performing the control tie-in to the Johnson Metasys Building Automation System;

    • self-performing the chilled water insulation work;
    • the IRS client spent no additional funds on the installation because the FSE workforce was already in place as a part of the ongoing maintenance workforce.


Start Up
New chiller start-up took place on Friday, June 18, exactly one week after the chiller was delivered to the job site. Part load performance of the new chiller is expected to be 30-40 percent less than the old chiller.

Recent Update
  • At part load on the old single compressor 220-ton machine, the lowest amp draw was 300 amps.


  • However, on the new chiller, with two (2) compressors, we have recorded part load amp draw as low as 60 amps.